Corrosion Resistance of Magnesium Ammonium Phosphate Cement-Based Coatings Modified by Calcium Sulfoaluminate Cement on Carbon Steel in a Saline Medium
Publication: Journal of Materials in Civil Engineering
Volume 36, Issue 6
Abstract
Calcium sulfoaluminate (CSA) cement was used as an internal admixture to replace some of the magnesium oxide (MgO) in magnesium ammonium phosphate cement (MAPC) coatings. This experiment resulted in improved corrosion resistance and production cost savings for MAPC coatings on carbon steel surfaces. The corrosion resistance of coated carbon steel with different CSA doping concentrations was evaluated by electrochemical methods including Tafel polarization curves and electrochemical impedance spectroscopy (EIS). At the same time, 7-day flexural and compressive tests, Low-field nuclear magnetic resonance spectroscopy (NMR) test, X-ray diffraction (XRD), scanning electron microscope (SEM), and thermogravimetric and differential thermogravimetric techniques (TG-DTG) were performed on the modified coatings. Neutral salt spray tests confirmed the improved corrosion resistance of the coated carbon steel. Based on the results of the study, the best ratio of CSA-modified MAPC coatings was finalized. The addition of CSA improved the flexural and compressive strength of MAPC. At later stages of immersion, there was an increase in the polarization resistance value, and a significant increase in the anodic slope of the polarization curve. Furthermore, the overall low-frequency impedance value, coatings resistance, and charge transfer resistance all experienced a substantial increase. The microstructural study revealed that gradually hydrated during immersion to produce amorphous hydrated calcium sulfoaluminate gel, significantly improving the anticorrosion performance of the coated carbon steel. After the coated carbon steel were exposed to a neutral salt spray environment for 1,440 h, there was no bulging or flaking of the coatings surface, and no rusting of the carbon steel surface. The modified coatings effectively served as a protective layer.
Get full access to this article
View all available purchase options and get full access to this article.
Data Availability Statement
Data will be provided from the corresponding author on demand.
Acknowledgments
This work was supported by the College of Civil Engineering and Architecture, Jiangsu University of Science and Technology, Zhenjiang, Jiangsu, China.
References
Bender, R., et al. 2022. “Corrosion challenges towards a sustainable society.” Mater. Corros. 73 (11): 1730–1751. https://doi.org/10.1002/maco.202213140.
Cash, G. A., D. P. Schweinsberg, and G. A. Hope. 1990. “The corrosion rate of low carbon steel in stationary and stirred sugar juice: A mathematical analysis of polarization curves.” Corros. Sci. 30 (6): 543–554. https://doi.org/10.1016/0010-938X(90)90021-V.
Chi, L., Z. Wang, S. Lu, D. Zhao, and Y. Yao. 2019. “Development of mathematical models for predicting the compressive strength and hydration process using the EIS impedance of cementitious materials.” Constr. Build. Mater. 208 (May): 659–668. https://doi.org/10.1016/j.conbuildmat.2019.03.056.
Ding, Z., B. Dong, F. Xing, N. Han, and Z. Li. 2012. “Cementing mechanism of potassium phosphate based magnesium phosphate cement.” Ceram. Int. 38 (8): 6281–6288. https://doi.org/10.1016/j.ceramint.2012.04.083.
Fei, Y., Q. Wu, H. Ma, R. Yin, M. Akbar, N. Yang, Y. Lu, and K. Lu. 2023. “Study on anti-corrosion performance of composite modified magnesium ammonium phosphate cement-based coatings.” J. Build. Eng. 71 (Jul): 106423. https://doi.org/10.1016/j.jobe.2023.106423.
Feng, H., M. N. Sheikh, M. N. S. Hadi, L. Feng, D. Gao, and J. Zhao. 2018. “Interface bond performance of steel fibre embedded in magnesium phosphate cementitious composite.” Constr. Build. Mater. 185 (Oct): 648–660. https://doi.org/10.1016/j.conbuildmat.2018.07.107.
Fouladi, M., and A. Amadeh. 2013. “Comparative study between novel magnesium phosphate and traditional zinc phosphate coatings.” Mater. Lett. 98 (May): 1–4. https://doi.org/10.1016/j.matlet.2013.01.061.
Glasser, F. P., and L. Zhang. 2001. “High-performance cement matrices based on calcium sulfoaluminate–belite compositions.” Cem. Concr. Res. 31 (12): 1881–1886. https://doi.org/10.1016/S0008-8846(01)00649-4.
Han, W., H. Chen, X. Li, and T. Zhang. 2020. “Thermodynamic modeling of magnesium ammonium phosphate cement and stability of its hydration products.” Cem. Concr. Res. 138 (Dec): 106223. https://doi.org/10.1016/j.cemconres.2020.106223.
Haque, M. A., and B. Chen. 2019. “Research progresses on magnesium phosphate cement: A review.” Constr. Build. Mater. 211 (Jun): 885–898. https://doi.org/10.1016/j.conbuildmat.2019.03.304.
Hou, B., X. Li, X. Ma, C. Du, D. Zhang, M. Zheng, W. Xu, D. Lu, and F. Ma. 2017. “The cost of corrosion in China.” npj Mater. Degrad. 1 (1): 4. https://doi.org/10.1038/s41529-017-0005-2.
Isakhani-Zakaria, M., S. R. Allahkaram, and H. A. Ramezani-Varzaneh. 2019. “Evaluation of corrosion behaviour of Pb- electrodeposited coating using EIS method.” Corros. Sci. 157 (Aug): 472–480. https://doi.org/10.1016/j.corsci.2019.06.023.
Jia, L., F. Zhao, K. Yao, and H. Du. 2021. “Bond performance of repair mortar made with magnesium phosphate cement and ferroaluminate cement.” Constr. Build. Mater. 279 (Apr): 122398. https://doi.org/10.1016/j.conbuildmat.2021.122398.
Jia, M., and J. Xu. 2008. “Development of thermal insulation coatings.” [In Chinese.] New Chem. Mater. 36 (11): 99–102.
Khabaz, A. 2017. “Analysis of sliding mechanism of straight steel fibers in concrete and determine the effect of friction.” Arch. Civ. Mech. Eng. 17 (3): 599–608. https://doi.org/10.1016/j.acme.2017.01.005.
Le Rouzic, M., T. Chaussadent, G. Platret, and L. Stefan. 2017a. “Mechanisms of k-struvite formation in magnesium phosphate cements.” Cem. Concr. Res. 91 (Jan): 117–122. https://doi.org/10.1016/j.cemconres.2016.11.008.
Le Rouzic, M., T. Chaussadent, L. Stefan, and M. Saillio. 2017b. “On the influence of Mg/P ratio on the properties and durability of magnesium potassium phosphate cement pastes.” Cem. Concr. Res. 96 (Jun): 27–41. https://doi.org/10.1016/j.cemconres.2017.02.033.
Li, G., J. Zhang, and G. Zhang. 2017. “Mechanical property and water stability of the novel CSA-MKPC blended system.” Constr. Build. Mater. 136 (Apr): 99–107. https://doi.org/10.1016/j.conbuildmat.2017.01.036.
Ma, H., B. Xu, and Z. Li. 2014. “Magnesium potassium phosphate cement paste: Degree of reaction, porosity and pore structure.” Cem. Concr. Res. 65 (Nov): 96–104. https://doi.org/10.1016/j.cemconres.2014.07.012.
Ma, S., Z. Zhang, X. Liu, and F. Han. 2023. “Quantitative characterization of the early hydration of magnesium potassium phosphate cement: In-situ experiment with low field NMR.” Constr. Build. Mater. 377 (May): 131066. https://doi.org/10.1016/j.conbuildmat.2023.131066.
McCafferty, E. 2005. “Validation of corrosion rates measured by the Tafel extrapolation method.” Corros. Sci. 47 (12): 3202–3215. https://doi.org/10.1016/j.corsci.2005.05.046.
Nicard, C., C. Allély, and P. Volovitch. 2019. “Effect of Zn and Mg alloying on microstructure and anticorrosion mechanisms of Al-Si based coatings for high strength steel.” Corros. Sci. 146 (Jan): 192–201. https://doi.org/10.1016/j.corsci.2018.10.037.
Pang, B., J. Liu, B. Wang, R. Liu, and Y. Yang. 2021. “Effects of K-struvite on hydration behavior of magnesium potassium phosphate cement.” Constr. Build. Mater. 275 (Mar): 121741. https://doi.org/10.1016/j.conbuildmat.2020.121741.
Peng, Y. M., C. Unluer, and J. Y. Shi. 2021. “Rheo-viscoelastic behavior and viscosity prediction of calcium sulphoaluminate modified Portland cement pastes.” Powder Technol. 391 (Oct): 344–352. https://doi.org/10.1016/j.powtec.2021.06.023.
Polyakov, N. A., I. G. Botryakova, V. G. Glukhov, G. V. Red’kina, and Y. I. Kuznetsov. 2021. “Formation and anticorrosion properties of superhydrophobic zinc coatings on steel.” Chem. Eng. J. 421 (Oct): 127775. https://doi.org/10.1016/j.cej.2020.127775.
Poorqasemi, E., O. Abootalebi, M. Peikari, and F. Haqdar. 2009. “Investigating accuracy of the Tafel extrapolation method in HCl solutions.” Corros. Sci. 51 (5): 1043–1054. https://doi.org/10.1016/j.corsci.2009.03.001.
Rodriguez, A. A., C. M. Miller, and C. N. Monty. 2020. “Field testing and cost-benefit evaluation of corrosion-protective coatings on winter maintenance equipment in the state of Ohio.” J. Cold Reg. Eng. 35 (1): 04020031. https://doi.org/10.1061/(ASCE)CR.1943-5495.0000239.
Šoljić, I., I. Šoić, L. Kostelac, and S. Martinez. 2022. “AC interference impact on EIS assessment of organic coatings using dummy cells, calibration foils and field exposed coated samples.” Prog. Org. Coat. 165 (Apr): 106767. https://doi.org/10.1016/j.porgcoat.2022.106767.
Song, M., C. Wang, Y. Cui, Q. Li, and Z. Gao. 2021. “Mechanical performance and microstructure of ultra-high-performance concrete modified by calcium sulfoaluminate cement.” Adv. Civ. Eng. 2021 (Aug): 4002536. https://doi.org/10.1155/2021/4002536.
Soudée, E., and J. Péra. 2000. “Mechanism of setting reaction in magnesia-phosphate cements.” Cem. Concr. Res. 30 (2): 315–321. https://doi.org/10.1016/S0008-8846(99)00254-9.
Stengel, T. 2009. “Effect of surface roughness on the steel fibre bonding in ultra high performance concrete (UHPC).” In Proc., Nanotechnology in Construction 3, 371–376. Berlin: Springer.
Tan, Y., H. Yu, W. Bi, N. Wang, and N. Zhang. 2019. “Hydration behavior of magnesium oxysulfate cement with fly ash via electrochemical impedance spectroscopy.” J. Mater. Civ. Eng. 31 (10): 04019237. https://doi.org/10.1061/(ASCE)MT.1943-5533.0002827.
Tang, H., J. Qian, J. Qin, Z. Li, X. Jia, Y. Yue, and F. Dai. 2023. “Electrochemical behavior of steel bars in magnesium phosphate cement.” Cem. Concr. Res. 169 (Jul): 107167. https://doi.org/10.1016/j.cemconres.2023.107167.
Van Phuong, N., and S. Moon. 2014. “Comparative corrosion study of zinc phosphate and magnesium phosphate conversion coatings on AZ31 Mg alloy.” Mater. Lett. 122 (May): 341–344. https://doi.org/10.1016/j.matlet.2014.02.065.
Wagh, A. S. 2016. Chemically bonded phosphate ceramics, 17–34. Amsterdam, Netherlands: Elsevier.
Wagh, A. S., and S. Y. Jeong. 2003. “Chemically bonded phosphate ceramics: I, A dissolution model of formation.” J. Am. Ceram. Soc. 86 (11): 1838–1844. https://doi.org/10.1111/j.1151-2916.2003.tb03569.x.
Wang, D., Y. Wang, K. Ma, C. Dai, J. Wang, J. Wang, and F. Pan. 2023. “Portland cementitious coating with autogenerated oxide film and its anticorrosion behaviour on magnesium alloy.” J. Mater. Sci. Technol. 176 (Mar): 99–111. https://doi.org/10.1016/j.jmst.2023.04.079.
Wang, D., Y. Yue, T. Mi, S. Yang, C. McCague, J. Qian, and Y. Bai. 2020. “Effect of magnesia-to-phosphate ratio on the passivation of mild steel in magnesium potassium phosphate cement.” Corros. Sci. 174 (Sep): 108848. https://doi.org/10.1016/j.corsci.2020.108848.
Wang, X., X. Hu, J. Yang, L. Chong, and C. Shi. 2022. “Research progress on interfacial bonding between magnesium phosphate cement and steel: A review.” Constr. Build. Mater. 342 (Aug): 127925. https://doi.org/10.1016/j.conbuildmat.2022.127925.
Wang, Z., J. Li, Y. Wang, and Z. Wang. 2017. “An EIS analysis on corrosion resistance of anti-abrasion coating.” Surf. Interfaces 6 (Mar): 33–39. https://doi.org/10.1016/j.surfin.2016.11.003.
Wenchang, W., H. Jiacheng, Q. Shuiping, H. Yan, and K. Dejun. 2023. “Effect of Ti mass fraction on microstructure, salt spray corrosion and electrochemical performances of laser cladded Fe90–6% coatings.” Mater. Today Commun. 35 (Jun): 106077. https://doi.org/10.1016/j.mtcomm.2023.106077.
Yin, S., H. Yang, Y. Dong, C. Qu, J. Liu, T. Guo, and K. Duan. 2021. “Environmentally favorable magnesium phosphate anti-corrosive coating on carbon steel and protective mechanisms.” Sci. Rep. 11 (1): 197. https://doi.org/10.1038/s41598-020-79613-3.
Zhang, G., G. Li, and T. He. 2017a. “Effects of sulphoaluminate cement on the strength and water stability of magnesium potassium phosphate cement.” Constr. Build. Mater. 132 (Feb): 335–342. https://doi.org/10.1016/j.conbuildmat.2016.12.011.
Zhang, J., H. Ma, H. Pei, and Z. Li. 2017b. “Steel corrosion in magnesia–phosphate cement concrete beams.” Mag. Concr. Res. 69 (1): 35–45. https://doi.org/10.1680/jmacr.15.00496.
Zhi, Y., Q. Wu, H. Ma, Y. Wu, M. Akbar, X. Zhao, and N. Yang. 2023. “Effect of zinc oxide on corrosion resistance of magnesium ammonium phosphate cement-based coating.” Constr. Build. Mater. 398 (Sep): 132473. https://doi.org/10.1016/j.conbuildmat.2023.132473.
Information & Authors
Information
Published In
Journal of Materials in Civil Engineering
Volume 36 • Issue 6 • June 2024
Copyright
© 2024 American Society of Civil Engineers.
History
Received: Jun 15, 2023
Accepted: Oct 20, 2023
Published online: Mar 27, 2024
Published in print: Jun 1, 2024
Discussion open until: Aug 27, 2024
Authors
Metrics & Citations
Metrics
Citations
Download citation
If you have the appropriate software installed, you can download article citation data to the citation manager of your choice. Simply select your manager software from the list below and click Download.